Automatic machine tool



Sept. 1, 1959 Filed D60. 27, 1957 17 Sheets-Sheet l RECORD 10' CARD 114o CARD READER COUNTER 25 51 CONTROLLER PULSE GENERATOR NE' 3e l l 37 i\sP|NDLE FEED SPINDLE sPEED/ CONTROL CONTROL L Y TOOL MATR|X ROTAT|ON LCONTROL i A,29

wRENCHlNG 'MECHANlsM PHOTOCELL V VTBRATION PICKUP TA`BLE *52 COORDINATEONTR L A FIG- l a INVENTOR. MARR MORGAN W ML AGENT Sept. 1, 1959 M.MORGAN AUTOMATIC MACHINE TooL Filed Dec. 27, 1957 17 Sheets-Sheet 2Sept. 1, 1959 M. MORGAN 2,901,927

AUTOMATIC MACHINE TOOL Filed Dec. 27, .1957 17 Sheets-Sheet 3 FIG--3..

Sept. l, 1959 M. MORGAN 2,901,927

AUTOMATIC MACHINE TOOL Filed Dec. 27, 1957 17 Sheets-Sheet 4 Sept. 1,1959 M. MORGAN 2,901,927

AUTOMATIC MACHINE TOOL Filed Deo. 27, 1957 17 Sheets-Sheet 5 34-'35MATRlX LOCATION 36-37 SPINDLE SPEED RANGE 39-42 DEPTH OF FEED FIG- 5-Sept. 1, 1959 M. MORGAN AUTOMATIC MACHINE TOOL 17 Sheets-Sheet 6 FiledDec. 27, 1957 TIG- 7- 123 BBB CCC 45 BB CC Sept. 1, 1959 M. MORGANAUTOMATIC MACHINE TOOL 17 Sheets-Sheet 7 Filed n ec. 27, 1957 HUH@ M.MORGAN AUTOMATIC MACHINE TOOL y :L7l Sheets-Sheet 8 Filed Dec. 27, 1957CARD 2 SEQUENCE COLUMN CARD 1 CARD l CBB Sept. 1, 1959 M MORGAN2,901,927

v AUTOMATIC MACHINE TOOL Filed Dec. 27, 1957 17 Sheets-Sheet 9 M311 /291Res FI Jf-3oe I I f292 *I 4/307 I I [293 Im, *I #-308A I I [294 Iz P IP309 I I lf295 ITI I #-310 I I rage Im -1 l Qb R21-f -w Sept. 1, 1959 M.MORGAN AUTOMATIC MACHINE TooL 17 Sheets-Sheet 10 Filed Deo. 2'?, 1957LELE/S16 -l lllllllilL Q @am sept. 1,1959 M. MORGAN 2,901,927

AUTOMATIC MACHINE TOOL Filed De. 27, 1957 17 Sheets-Sheet 11 Sept. l,1959 M. MORGAN AUTOMATIC MACHINE TooL y 1'7- Sheets-Sheet 12 Filed Deo.27, 1957 *Fre la b- VT LA 'Lime Sept. 1, 1959 M. MoRGAN AUTOMATICMACHINE TOOL 1'7 Sheets-Sheet 13 Filed Dec. 27, 1957 COLUMN 35 Sept. 1,1959 M. MORGAN AUTOMATIC MACHINE Tool.

` 17 sheets-sheet 14 Filed Dec. 27, 1957 Sept. l, 1959 M. MORGAN2,901,927

AUTOMATIC MACHINE Toor.

Filed bec. 27, 1957 17 sheets-sheet 15 Sept'. 1, 1959 M. MORGANAUTOMATIC MACHINE Toor.

17- Sheets-Sheet 16 Filed Dec. 27, 1957 ICB- 16o Sept. 1, 1959 M. MORGANAUTOMATIC MACHINE TOOL Filed Dec. 27, 1957 I 17 Sheets-Sheet 1'7 i l l Il i i l l 1 l l l I l l I I l l l l i l United States Patent O AUTOMATICMACHINE TOOL Mark Morgan, Poughkeepsie, N.Y., assignor to InternationalBusiness Machines Corporation, New York, N .Y., a corporation of NewYork Application December 27, 1957, Serial No. 705,701

20 Claims. (Cl. 77-4) I'his invention relates to data programmedmachinery and in this particular embodiment to a punch card controlledjig boring machine wherein the data from said punched card operates acontroller which `selects a desired tool for s-aid jig borer, positionsthe jig borer table to a predetermined coordinate position, selects thecorrect feed and speed of the spindle and controls the depth of theboring operation to be performed by the selected tool.

In the manufacture of card feed units such as the one used in thisinvention and in other machinery wherein a large number of holes must beaccurately bored, a jig boring machine is utilized to drill or borethese holes with a high degree of accuracy both as to location and tohole diameter. The use of these boring machines requires time consumingand laborious preparation by highly skilled operators which thereforerequires both a large outlay in labor and the time of skilled mechanics.In the actual machining of the parts, continuous operator attendance `isnecessary and the accuracy of the finished part is in a large partdependent on the skill of the operator.

For these reasons a machine tool which has all the attributes of aprecision boring machine and yet can be accurately operated with aminimum of skilled supervision is highly desirable for production work.

In boring operations where a large number of holes 'of variable depthand diameter are to be performed on va single workpiece, a number ofvariables are encountered which add to the complexity of the boringoperation. Enumerating these variables it can be seen that:

A large number of tools are required for both variable hole diameter andthe various operations which are performed by boring tools such asdrilling, boring, counter boring, and counter sinking.

The workpiece must be accurately positioned on a coordinate basis inorder that the boring operation is performed at the desired location.

Spindle feeds and speeds must be determined for each boring operation.

The depth of boring in the workpiece must be accurately determined inorder to insure precision in nished pieces.

The sequence of operations in determining the holes 'to be bored whichinvolve all other factors enumerated in the preceding paragraphs.

While these variables must be determined for each individual workpiecein any event, it is quite evident that there is one sequence which willresult in the completion of a workpiece in a shorter time interval thanyany other sequence. With present day computers and programmingtechniques, problems such as sequencing operations can be resolved. Evenwithout the use of computing machinery, the problem of sequence ofoperations of machine tools is better carried out by persons morefamiliar with mathematical techniques than operators of the machineconcerned.

The present invention is adapted for unit record card ICC controlwherein a single record card controls all variable data for each hole. Adeck of cards is arranged for each individual type of workpiece and thusform a series of input datum to control the machine throughout itsentire operation.

It is therefore an object of this invention to provide a data programmedmachine tool.

It is a further object of this invention to provide a digital dataprogrammed machine tool.

It is another object of this invention to provide a digital p dataprogrammed machine tool controlled by punched cards.

Yet another object of this invention is to provide a machine toolwherein individual tools may be selected for use in the machine undeldigital data control.

A further object of this invention is to provide a data reading deviceoperable to disregard all sequential readings of identical data.

Another and further object of this invention is to provide a dataprogrammed jig borer in which all variables of spindle feed and speedare controlled by said data.

Other objects of the invention will be pointed out in the followingdescription and claims and illustrated in the accompanying drawings,which disclose, by way of examples, the principle of the invention andthe best mode, which has been contemplated, of applying that principle.

In the drawings:

Fig. 1 is a schematic illustration of the instant invention withappended flow chart.

Fig. 2 is a side elevation view of the wrenching mechanisrn and the toolstorage matrix.

Fig. 3 is a top plan view of the wrenching mechansim taken along line3-3 of Fig. 2.

Fig. 4 is a side elevation of the rotating mechanism of the tool matrixwith side removed.

Fig. 5 is an isometric view of a tool carried in the tool matrix.

Fig. 6 shows the format for the punched card used in the presentinvention.

Fig. 7 `is a schematic illustration of the card reader.

Fig. 8 shows schematically the gauging rods of the boring machine.

Fig. 9 shows the motor control for spindle feed.

Figs. l0 through 17 illustrate the electrical circuitry of the presentinvention.

In providing a general description of the instant invention, referencewill be made to Fig. l which shows the complete mechanical structurewith schematic illustration of all electrical control circuitry andinformation ow. A more detailed description will be made hereinafter ofmany of the various units and their mode of operation; so for thepresent general explanation, a simple statement of function will be madefor these.

A record card 10, such as shown in Fig. 6, is utilized to storeinformation for operation of the jig borer with punched holes beingprovided at various locations which are referable to certain functionsand provide magnitudes or values to be assumed by the apparatus whichrepresents these functions. Each card 10 represents the data for onehole location.

With reference to Fig. 6, it can be seen that a punched card such asused in the present invention is divided up into columns and l2 rows. Bypunching a hole in a selected row and column intersection, an indicationis made of both value (row) and Variable (column). Rows l2 and ll arenot ordinarily used in this invention since all necessary punchings canbe made in rows 0-9. Row l2 and ll, however, could be used if needed.

At present, columns l through 49 are used for a Variety of purposes inthe present invention. Of the columns which have any bearing on thefollowing description, there are:

(l) Columns l through l4-for comparison of cards against one another toinsure that all cards belong in that deck.

(2) Columns 15 through 17-sequence number of card in deck to insureproper sequence of operations in boring operations.

(3) Columns 22 through 27-designation of hole location in X coordinatedistance to six digits (XX.- XXXX) are provided.

(4) Columns 28 through 33designation of hole location in Y coordinatedistance, six digits (XX.- XHX) are provided.

(5) Columns 34 and 35--tool storage matrix location for selection ofproper tool for instant boring operation.

(6) Columns 36 and 37-spindle speed.

(7) Column 38-feed of spindle.

(8) Columns 39 through 42-depth of feed.

A card reader lll. such as shown in the patent to Page et al., PatentNo. 2,484,114, is utilized to sense the holes punched in the card 1t)and also the location of these punchings and transmit this data to acontroller 2S. Fig. 7 illustrates the card reader which consists of ahopper 11S for storing cards l@ to be read and feeding them one by oneto driving rolls 16 which move the cards into a sensing station 17. Onthe next card reading cycle, the same card is moved into the nextsensing station 1S and the card succeeding this first card is moved intothe first sensing station. A card stacker drum 19 receives cards fromsaid second sensing station and moves them to a stacker (not shown) intheir proper sequence. Two reading stations are utilized to check dataon succeeding cards against each other and the actual boring operationis controlled by the data from the card in the rst reading station. Thiscard is referred to as card 2 in subsequent descriptions.

Each sensing station has 960 brushes 2t) (l2 rows times 8O columns), onefor each hole position. The brushes 2G in this invention have beenconnected together in each column and separate sources of potential havebeen provided for each column (not shown in Fig. 7) so that each columnmay be selectively energized at the proper time in the sequence ofoperations. Directly below each set of brushes is a commutator block 21containing 96() individual segments each referable to a particular holelocation. An output lead is connected from each segment to any desiredpoint. lf there is a hole at any coordinate position, a potential willbe furnished to that lead when the column in which it is situated isenergized.

The controller 25 contains generally all the control circuitry necessaryto correlate the information transmitted from card reader 11 with thejig borer apparatus, and to route information from the card reader tothe apparatus as needed. The general circuitry for the controller isshown in Figs. 1G through 16.

A tool storage matrix 27, consisting of a rotatable, laterally movable,circular plate 28 with suitable supporting structure, has notches cutinto the periphery thereof for storing a plurality of tools. Electricalsignals from the controller 25' determine the position of the rotatableplate 2S with respect to the jig borer 29, both rotationally andlaterally, so that a particular tool may be moved in line with the jigborer and then moved laterally to a position beneath the spindle 34) ofthe jig borer. The details of this unit may be seen in Figs. 1, 2, 4,and 5.

The jig borer 29 is of the type illustrated in Patent No. 2,674,706 toKnosp et al. The commercial apparatus illustrated in Fig. l is ditferentfrom the patent in a number of respects, and one of these differences isillustrated more particularly in Fig. 8. As illustrated in Fig. l, aworktable 31 is movable on a coordinate '4 f basis to any one of aplurality of discrete positions determined by the information from thecontroller 25. A feed mechanism 36 is provided for moving the spindle 30at controlled linear velocities, while a speed mechanism 37 is providedfor rotating the spindle 30 at controlled angular velocities. In thepresent invention, both feed and speed are card controlled.

A wrenching mechanism 38 is provided beneath the throat of the jig borer29 to accept and tender tools from and to the tool matrix 27 and spindle30. In this operation, the wrenching mechanism may be thought of as anintermediary in exchanging tools for each subsequent operation requiringa change in tool.

An electronic counter i0 is preset by information from the card andOperates t0 make two measurements of the travel of the spindle Sti.These two measurements are controlled by a photocell 41 and light source42 and a vibration pickup 43. The pulse apparatus 44 is illustratedschematically in Fig. 9.

CYCLE OF OPERATION For ptnposes of illustration of the interrelationshipof the various elements shown in Fig. l, a tool 4S is shown held by thewrenching mechanism 38 with the spindle .3@ in a raised position. Thissituation represents a part of the cycle of operation subsequent to thecompletion of a boring operation (as described in Step 3 infra) justcompleted by tool 18. In order to provide an understanding of thepresent invention, the steps of operation will be described withreference to Fig. 1.

(l) The hole boring operation has been completed and the tool 48,secured in spindle Si?, is raised to a position intermediate the fullyraised position of spindle 30 and the position of the wrenchingmechanism which is open. Another card 10 has now been fed into the cardreader 11 upon a signal that the preceding operation has been completed.

(2) The fnst and second cards are compared for similarities to determinewhether it is necessary to change the position of the worktable 311and/or tool 48. In this instance, it will be assumed that it isnecessary to perform both operations and the controller 25 sets upproper circuits to initiate this action.

(3) The spindle feed control 36 is actuated and the spindle Sil is moveddown to a position opposite the wrenching mechanism .38 which is open.The wrenching mechanism 33 then closes and grips the tool 48. The speedcontrol 37 is actuated and the spindle rotates in a counterclockwisedirection t0 unscrew the tool 48. The spindle is then raised by means ofthe feed control 36 to its uppermost position. This is shown in Fig. l.During this period, the worlttable 31 is being positioned to the desiredX-Y coordinate position beneath the spindle Sti.

(4) The tool storage matrix plate 23 moves to an in position and thetool is gripped in the tool holding slot from which it originated. Thewrenching mechanism 33 opens and the tool is stored in the matrix plate.The matrix plate now rotates to bring the next selected tool 43 in linewith the wrenching mechanism which closes upon this tool. The toolstorage matrix plate 28 moves out leaving the selected tool in thewrenching mechanism.

(5) The spindle Si) moves downward in response to the feed control 36and rotates by means of the spindle control 37 in a clockwise directionto screw the tool up into itself. After the tool isl secured, thewrenching mechanism 38 opens and the tool is free to rotate with thespindle Sil. At this time, the worktable should be positioned to thedesired X-Y coordinate position beneath the spindle 3th.

(6) If the worktable 31 is properly positioned, the spindle Sti and toolbegin to move downward. Previous to this time, a predetermined number(manually set) been entered into the counter 4t) indicative of adisandjourualed'in the top wall. on a plate71 supportedby said housing65 and connects `motion from a motor shaft clutch disc 72 to a gear 73.carried on a shaft journaled between said support plate tance from thephotocell 41 toward the workpiece 50. When the tip of the tool crossesthe light beam from 'light source 42, appropriatecircuitry is selectedto allow vpulses from the .pulse generator A51 to be entered into thecounter. When the pulses into the counter equal the number preset intothe counter, the vibration pickup 43 is rendered operative and the depthof the hole, as punched on the record card l10, is set into the counter.At this time, nopulses fromthe -pulse generator are being entered intothe counter 40. When the pickup 43 is rendered operative, the top of thetool is A6 of an inch, ap-

l,proximately, from the workpiece 50. This is to prevent spuriousvibrations from operating the vibration pickup '43, and is thesolefunction of the manual setup of the counter 40 which would vary withthe thickness of the workpiece.

(7) The tool is rotated and fed toward the workpiece at a predeterminedspeed. When the tool contacts the workpiece 50, a signal is transmittedto the counter 40 to accept pulses from the pulse generator. The feedand speed of the spindle 30 are set as determined by the holes punchedin the card. When he counter 40 is satistied by the number of pulses,and consequently the depth of the holle, the feed control isde-energized and the hole is properly bored.

(8) The spindle rotation is terminated and the spindle is fed toaposition above the wrenching mechanism 38, 'and another card is fedintofthe card reader.

Tool storage matrix The tool storage matrix 27 is shown in Fig. 1 andconsists in a stand 56 into which is fixed a vertically extendingsupporting column 57. `On the uppermost section of :the column is avertically movable sleeve 58 setltable to a predeterminedheight foralignment with said machine tool. Extending from said sleeve are apairof ways 59 and 60 lsecured at their outer ends by a cap 61.

`On the ways lis mounted a slide 62 movable to either a positionadjacent the vertical sleeve 58 or adjacent the cap 61. 'A hydrauliccylinder and piston (not shown) furnishes the motive force for movingthe slide to one position or another in response to the introduction ofhydraulicpressure either infrontof or behind the piston.

Suspended between ways on the slide is the rotational Ycontrolmechanism-62 for the tool plate 28, see Fig. 4.

4As shownin this'gure, a motor 63 is mounted -on top of a housing 65andhas its shaft 64 extending through A clutch 70 is mounted l71 and thelower portion of said housing 65. This gear 73 forms arst gear in aseries 73-76 of reduction gears. The lastf gear in this series'76 -ismounted for rotation about a column 77 lixed from a mounting block 78 onlthe underside of lthe top portion of the housing and ex- `tending downto a nut 79 fastened on the underside of the matrixfbottom plate 97.

Connectedlto this'last gear 76 is a sleeve 84 surrounding the verticalsupporting column 77 and journaled in a bearing-85 secured to the topside of the bottom portion of the housing v65. This sleeve 84 extendsthrough the bottom of lthe housing, through a piece 86 secured to thehousing, through a commutator disc 87 iixed to the piece 86 by members88 and 89, through a rotatable commutator disc 90 and supportingstructures 91 and 92 iixed to the sleeve, through two partial bearings93 and 9'4 to the tool storage plate 28 anchored to the sleeve Vandtothe detent plate 96 supported on a plate fixed by the verticallyextending shaft.

The operation is therefore that thesleeve 84, rotatable on thevertically extending column 77, moves the rotat- 96 corresponding eachto an individual tool.

able .commutator disc 90, the tool storage plate 28 and the detentlplate 96. The commutator discs are shown in Fig. 13 withthe rings 356through 360 being mounted on the movable commutator 90 and the brushesbeing mounted on the fixed commutator 87. These control the rotation ofthe tool disc 28 by means of a control for the motor 63 to be describedin connection with the electrical circuitry.

On the fixed plate 97 secured to the 'vertically extending column 77 ismounted an electrically controlled air operated solenoid 98 whichfunctions to move a detent 99 into one of the serrations formed in saiddetent plate This is to insure positive positioning of the tool storageplate 28 with -respect to the jig borer Aspindle which is spaced apartby a spacer 106. The partial bearings 93 and 94 are fixed vertically bymembers 107 and 108 secured to housing 65 and plate 86, respectively. Adust cover 109 is secured to the plalte 86 and housing 65 and surroundsthe commutators. The light source 42 is mounted on the underside of theplate 97 and contains a lens assembly l110 for directing :a beam oflight toward the photocell 41, Fig. l.

The tool 48, Figs. 2 and 5, consists of a threaded end 111 for insertioninto the spindle of the boring machine, a tapered portion 112 forinsuring the transmission of high torque when the tool is lirmly securedin the spindle 30, a hexagonally'shaped nut 113, a collar 114 directly`below said nut 113 and a reduced shaft member 119 terminating in asquare block 115. This combination vmay be machined from one piece orconstructed from the elements. A screw 116 threaded in said block hasits lthreads meshing with a threaded block 117 keyed therein forrelative movement to establish centering of tool bits -118 to be-placedin said last-mentioned blocks 117. The tool bits per se are fastened tothe lower block in `any desiredmanner. The tool bit holders 111-117 areutilized in order to obtain a constant distance between the top of thetool storage plate 28 and the threaded portion 111 to be inserted intothe spindle 30 since the tools themselves vary in length.

The slots 126 in the storage plate, Fig. 5, have keys 127 secured to theperiphery of the slots 126 which slide in the way 119 formed between thecollar 114 and Isquareshanks 115 of the tool holder. kA stanchion 128 ismounted on said tool storage plate 28 directly behind each slot 126 andhas `journaled therein two wiping sections 129 urged by ilat springs`130 into engagement. These lwiping members are formed to conform to theshape of the shank V112 of the tool holder and have radially extendingfingers 131 containing chamois 132 for wiping the shank of the tool whenit is inserted into the slot 126 for storage.

Wrenchz'ng mecha'nism The wrenching mechanism 38 of the presentinvention is ixed beneath the head of the boring machine as shownclearly in Fig. 2, and performs two separate and distinct functions:

(l) To remove or insert a tool into the tool storage plate 28.

(2) To hold the tool for insertion into the spindle 30 or remove thetool from the spindle.

The wrenching mechanism 38 is secured by channel members 137 directlybeneath the head of the boring machine 29 in any suitable manner such asby welding. As `shown in Fig. 2, a tool 48 is -being held by thewrenching mechanism 38 for insertion into the spindle 30 of the boringmachine 29. The storage plate 28 is moved to a position removed from thespindle and will not be moved back into operative position untiltheftool now in the mechanism is to be replaced in the storage plate.

The wrenching mechanism 38 is formed of plates k138 and 139 spaced apartby 'members 140 secured to

